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Sisu Fortius Manual PDF
Sisu Fortius Manual PDF
Sisu Fortius Manual PDF
Fortius Series
Engines
Workshop Manual
03 08
GENERAL
TO THE USER
This Workshop Manual is intended to facilitate workshop operations and repair work.
Fortius series engines (types 33, 44, 66, 74 and 84) are mainly the same in construction, so the same repair instruc-
tions usually apply to different engine types. The differences between the various engine types which affect repair
work have been mentioned in technical data and repair instructions. All measurements are in millimetres and valid
when the temperature of the parts is +20°C, unless otherwise stated.
Before starting the repair work read the safety instructions in the beginning of this book. Make sure that you have
all necessary tools, parts and accessories at your disposal. The special tools mentioned in the work instructions are
not all essential, but they speed up and facilitate the work and contribute to successful execution of work. An engine
which has undergone repairs must be run in just like a new one.
Should the engine require measures not described in this manual, please consult your local agent or the Service
Department of Sisu Diesel Inc., Linnavuori, Finland. To facilitate consulting, find out the following facts about the
engine before contacting us:
- engine type
- engine number
- application or equipment
- hours operated or kilometres driven.
In this Workshop Manual the regular service procedure is not handled as this is explained in the Fortius series
Instruction Manual.
As Sisu Diesel Inc. is continuously developing the products, all rights are reserved without separate notice to change
the adjustments, accessories and service- and repair procedure.
6 0
General
Make sure that the place of the repair and the sur- Always disconnect the minus (-) wire of the battery
rounding gives the possibility for safe working. when doing service or repair of the electric sys-
tem.
Always be sure of the cleanness and the good
order of the repairing place. At temperatures on excess of 300°C, e.g. if the
engine is burnt by a fire, the viton seals of the
Do not use faulty or otherwise useless tools. engine (e.g. the undermost o-ring of the cylinder
liner) produce very highly corrosive hydrofluoric
Remove all finger rings, chains and watch before acid. Do not touch with bare hands, viton seals
starting work. subjected to abnormally high temperatures.
Always use neoprene rubber or heavy duty gloves
Use up-todate protection equipment when you and safety glasses when decontaminating. Wash
work. For example eye protection as working with the seals and the contaminated area with a 10%
compressed air for cleaning, grinding, hammering calcium hydroxide or other alkali solution. Put all
or other work. removed material in sealed plastic bags and
deliver them to the point stated by the Authorities
Use lifting device for lifting and transporting heavy concerned. Note! Never destroy viton-seals by
(over 20 kg) pieces. make sure of good condition burning!
of lifting hooks and chains. The lifting ears on the
engine must not be applied by side forces when When checking fuel injectors do not let the jet of
lifting. high pressure fuel contact your skin. The fuel pen-
etrates the skin causing severe injuries. Contact
Never work under an engine that is left handling your doctor immediately!
under a lifting device or lifted up by a jack. Always
use strong supports before starting the work. The fuel, lubricating oil and coolant cause irritation
in skin contact for long time.
Use only genuine SisuDiesel spare parts.
0 7
General
Turbocharged engine
W = by-pass turbo
T = standard turbo
Basic type
74 = cylinder displacement, decilitres
E = electronic engine management
D = mechanical injection pump
e17*97/68EA*97/68EA*0016*00
FINLAND
Type SISUDIESEL 74.234 ETA
The engine serial number is always stamped on the cy-
ignition engines
Cust.
Part nr N 5853420
EU
Family D20AEE
EPA
Family YSIDL07.4C2A
Displacement: 7.4 l Fuel: 2-D fuel oil
Assembled by:
M07575
M07576
8 0
General
Partno 836864630
Cust.
Partno
Note! The engine meets EU97/68/EC Stage 2 and EPA Engine
Serial nr M07575
40 CFR 89 Tier 2 emission requirements. Type 74 ETA
A A
Weight of engine
Engine Weight
type kg *)
33 280
44 340
66 510
74 520
84 660
0 9
General
CONSTRUCTION
Technical data
Engine type 33 44 66 74 84
Fuel system
Injection pump
Stanadyne DB4
Bosch VP 30
Bosch VP 44
Bosch P 7100
Fuel The fuel must be according to norm EN 590,
see page 93
Injection order 1-2-3 1-2-4-3 1-5-3-6-2-4
Feed pressure at idle speed 1,0...1,2 bar
Injector Five-hole nozzle
Opening pressure of the nozzle 270 bar
Adjusting pressure of the nozzle 278 bar
Fuel filters
Pre-filter Stanadyne 30 µ
Final filter Stanadyne 5 µ
Lubrication system
Oil pressure in hot engine at running speed 2,5...5,0 bar
Oil pressure at idle speed, min 1,0 bar
Oil capacity see page 73
Oil quality requirements see page 73
Cooling system
Number of thermostats 1 1 1/2 2 2
Opening temperature ∅ 54 mm = 79°C ∅ 67 mm = 83°C
Coolant quality requirements see page 74
10 0
General
General
The Fortius engine series consists of water-cooled in-
line diesel engines with three, four and six cylinders.
The turbocharged engines are equipped with wet, chan-
geable cylinder liners.
Cylinder block
The cylinder block is the main body of the engine, to
which other engine parts are attached. Wet and repla-
ceable cylinder liners are supported at the middle which
reduces vibrations and directs coolant circulation main-
ly to the upper part of the liners.
The seal between the cylinder liner lower part and the
cylinder block is achieved by three o-rings, which are
fitted in grooves in the liner. The upper part is sealed by
the cylinder head gasket.
Flywheel housing
The flywheel housing is fitted at the rear end of the cy-
linder block. The seal for the crankshaft rear end is pla-
ced in a bore in the housing. The starter motor fixing
point is fitted in the flywheel housing.
0 11
General
33- and 44-engines have one cylinder head. 66-, 74- The piston is made of an eutectic aluminium alloy. In the
and 84-engines have two cylinder heads which are upper face of the piston there is a combustion chamber.
exchangeable with each other and also with the cylinder The shape of the chamber is intended to maximise the
head on the 33-engine. Each cylinder has its own inlet mixture of air and fuel. The upper ring location is formed
and exhaust ports located on either side of the head. in a cast iron ring which is cast in the piston. In addition,
Between hot exhaust valves a cool inlet valve is fitted to the piston is graphite coated to ensure correct running-
balance the thermal load. in.
Cylinder head bolts are high tensile bolts which are tigh- The piston has three rings. The upper molybdenum-co-
tened up to yield limit using angle tightening principle. ated ring has a wedge-shaped cross-section. On some
Due to the large stretch the tightening forces are kept slight supercharged engines the upper ring is right-ang-
constant during the whole lifetime and retightening is led. The middle ring is tapered and it fits into its groove.
unnecessary. The taper taking up the clearance. The oil control ring is
spring loaded and it has a two-stage, chromed scraping
The injector locations are machined directly into the cy- edge.
linder head. The inlet and exhaust valve guides are
identical and can be interchanged. Exhaust valves are Some four-cylinder engines (44) are equipped with a
fitted with separate valve seat rings. Also the engines balancer unit. The eccentric weights, which rotate at
with high output are equipped with separate inlet valve twice the engine speed, even out the vibration forces
seats. exerted by the movement of the pistons and the crank
mechanism.
Valve mechanism
The valve mechanism is operated by the camshaft
which is located in the cylinder block. The drive is trans-
ferred with the help of tappets and push rods. The
camshaft gear wheel is fitted with a press fit and fixed
with a key. Each bearing is lubricated by the force feed
lubrication system through drilled oilways in the cylinder
block.
12 0
General
Timing gears
33-, 44-, 66- and 74-engines
84-engines
6
Timing gears
1
1. Camshaft gear B
4
2. Idler gear 2 3
3. Injection pump gear
4. Coolant pump gear
5. Crankshaft gears
6. Oil pump gear
7. Small idler gear
8. P.T.O. gear
8
5
7
0 13
General
Lubricating system
7 3
5 6
2
Lubricating system (66- and 74-engines)
1. Oil pump
2. Oil pressure regulating valve
3. Oil filter
1 4. Turbocharger
5. Main oil gallery
6. Piston cooling nozzle
7. Oil pressure sensor
The engine has a pressure lubricating system in which The oil filter is of main flow type. It has a replaceable
the oil pump (gear pump) is attached to the cylinder cartridge mounted on the left side of the engine, 84-en-
block lower face. The oil is sucked up by the pump gines on the right side. At the bottom of the oil filter cart-
through a suction strainer. After the pump the oil is led ridge there is a by-pass valve for cold start or possible
through an oilway to the oil pressure regulating valve clogging of the filter.
via the oil cooler to the oil filter. After the filter, the oil is
led through the main oil gallery from which oilways Some engine types are equipped with a oil cooler loca-
branch out. The oil is led through the oilways in the main ted between the cylinder block and the oil filter. All oil
bearings and through the crankshaft to the big-end bea- that circulates through the filter also goes through the
rings. cooler and is cooled by the engine coolant circulating in
the oil cooler.
The oil is further directed from the main gallery to the
turbocharger and to a possible compressor. In addition, The 84-engines are equipped with an plate type oil coo-
the camshaft bearing points and the valve mechanism ler, that is situated on the right side of the engine above
get their lubrication oil via the main oil gallery. the filter. The cooler is of main flow type.
14 0
General
Cooling system
4
6
Cooling system (84-engine) In some 66- and 74-engines and 84-engines there are
two separate thermostats where one of them is steering
1. Radiator the by-pass of coolant liquid. The thermostats differ in
2. Coolant pump types and opening temperatures. When the coolant
3. By-pass pipe temperature is below the thermostat opening tempera-
4. Thermostats ture the coolant (A) circulates through the by-pass hole
5. Expansion tank into the coolant pump. The smaller, singleacting ther-
6. Oil cooler mostat (1) opens first (at 79°C) letting one part of the
coolant (B) into the radiator. Following the load inc-
rease, also the other thermostat (2) opens (at 83°C).
The coolant pump is attached to the front face of the cy- This is a double-acting type which closes the by-pass
linder block and the thermostat housing is mounted hole when it opens and directs the coolant (C) into the
above it. radiator. These engine models do not have any separa-
te winter-type thermostats.
On 84-engines, the gear driven coolant pump is at-
tached to the front face of the timing gear housing. The
thermostat housing is mounted on front end of the cylin-
der head. C
The system has the internal liquid circulation via the by-
pass pipe. The circulation is regulated by the 2-way
thermostat. This arrangement ensures a steady war-
ming-up of the engine under all conditions. 2
1 B
0 15
General
The filter system for the engine inlet air comprises a The turbocharger is a turbo-compressor driven by ex-
cyclone type pre-cleaner, and a paper filter which acts haust gas. The compact design of the turbocharger is
as the main filter. The incoming air is made to rotate in fast to react even during low revolutions. The turbochar-
the cyclone pre-cleaner. This causes most of the impu- ger is lubricated and cooled by the lubrication system of
rities to settle out and collect in the cyclone pre-cleaner the engine. EWA-engine is equipped with a by-pass tur-
dust collector. The paper filter comprises one or two bocharger where excessive air pressure is adjusted by
replaceable filter elements. The paper is corrugated a so-called by-pass channel. The boost pressure is ad-
and surrounded by a metal support. justed correctly by the manufacturer, and must not be
changed afterwards.
The impurities in the air collect at the larger filter ele-
ment which can be cleaned when necessary. The inner The compressed air is cooled on the air-to-air basis.
safety filter prevents impurities form entering the engine The air coming from the turbocharger has a temperatu-
should the main filter element break, or be fitted incor- re abt. 150°C which is cooled by the cooling air of the
rectly. engine. The intercooler's cell is ideally installed in front
of the radiator or side-by-side with radiator. The cooling
A mechanical or electrical service indicator can be of the compressed air stabilises the combustion, irres-
mounted on the filter housing or on the inlet pipe to pective of the temperature, and minimises the thermal
show when the filter cartridge is clogged. The inlet sys- and mechanical load of the engine thus lowering nitric
tem also includes the hoses between the air cleaner oxides (NOx) and particles (PT). Certain engine ver-
and the turbocharger and the turbocharger and the in- sions can also be equipped with an air-to-water inter-
take manifold. cooler. In that case, the engine specification is ETI.
16 0
General
TECHNICAL DATA
Cylinder block
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,250...13,320 mm
Main bearing housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm
Main bearing housing diameter (with bearing 8361 40950) . . . . . . . . . . . . . . . . . 92,000...92,025 mm
Cylinder liner location, diameter:
- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,514...124,554 mm
- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,000...123,040 mm
Inner diameter of camshaft bushing (fitted). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,010...50,070 mm
Height of cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428,170...428,430 mm
Cylinder liners
Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . 0,030...0,080 mm
Max. permissible height difference between liners (under same head) . . . . . . . . 0,02 mm
84-engines
Outer diameter of cylinder liner guide:
- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,975...125,000 mm
- at lower end of liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120,966...120,991 mm
Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111,000...111,022 mm
Cylinder head
Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,800...105,000 mm
Height of cylinder head after repair grinding (minimum) . . . . . . . . . . . . . . . . . . . . 104,000 mm
Inside diameter of valve guide (not fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000...9,015 mm
Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm
Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm
Position of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . 21 mm
0 17
General
18 0
General
Camshaft
Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,925...49,950 mm
Diameter of camshaft bearing journals (others that no. 1) . . . . . . . . . . . . . . . . . . 49,885...49,910 mm
Diameter of camshaft bearing journals nos 2, 3 and 4 (66/74/84-engines) . . . . . 49,865...49,890 mm
Inside diameter of camshaft bearing bushes (when fitted in position) . . . . . . . . . 50,010...50,070 mm
Diameter of camshaft bearing bores (others than no. 1). . . . . . . . . . . . . . . . . . . . 50,000...50,025 mm
Camshaft clearance in bearing bush no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,145 mm
Camshaft clearance in bearing bushes (others than no. 1) . . . . . . . . . . . . . . . . . 0,090...0,140 mm
Camshaft clearance in bearing bushes nos 2, 3 and 4 (66/74/84-engines) . . . . . 0,110...0,160 mm
Bearing bush tolerance in block (press fit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,080 mm
Diameter of bearing bush bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,620...55,650 mm
Camshaft end play with 0,5 mm gasket between cylinder block and timing gear
housing and between timing gear housing and front cover. . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Cam height (distance between back of cam and tip of cam):
- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,180...41,430 mm
- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,080...40,330 mm
Cam lift:
- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,38 mm
- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,28 mm
Camshaft max. permissible deflection (total indicator reading). . . . . . . . . . . . . . . 0,03 mm
Crankshaft
Crankpin diameter:
- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,981...68,000 mm
- 1. undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,731...67,750 mm
- 2. undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,481...67,500 mm
- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,981...67,000 mm
- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,481...66,500 mm
Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000...40,160 mm
0 19
General
Crankshaft, 84-engines
Crankpin diameter:
- standard . . . . . . . . . . . . ....... ...... ....... ...... ...... ....... . . . . 72,981...73,000 mm
- 1. undersize 0,25 mm . . ....... ...... ....... ...... ...... ....... . . . . 72,731...72,750 mm
- 2. undersize 0,50 mm . . ....... ...... ....... ...... ...... ....... . . . . 72,481...72,500 mm
- 3. undersize 1,00 mm . . ....... ...... ....... ...... ...... ....... . . . . 71,981...72,000 mm
- 4. undersize 1,50 mm . . ....... ...... ....... ...... ...... ....... . . . . 71,481...71,500 mm
Crankpin length . . . . . . . . ....... ...... ....... ...... ...... ....... . . . . 40,000...40,160 mm
20 0
General
Flywheel
Interference fit between ring gear-flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,425...0,600 mm
Before fitting the ring gear, heat up to a temperature of . . . . . . . . . . . . . . . . . . . . 150...200°C
Flywheel unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm max.
Max permissible axial wobble of flywheel clutch face, measured at inner edge
of clutch face on diameter 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06:ø200
Timing gears
Tooth backlash:
Crankshaft-idler gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear-camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear-fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Max. permissible side wobble of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm
Idle gear (slide bearing)
- Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,951...54,970 mm
- Inner diameter of idler gear bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,000...55,030 mm
Idle gear (slide bearing, 50 mm length shaft)
- Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,151...55,170 mm
- Inner diameter of idler gear bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,200...55,230 mm
Inner diameter of Idler gear hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,000...60,030 mm
Camshaft gear hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,025 mm
Camshaft end diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,043...32,059 mm
Timing marks:
Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre
between compression and power strokes.
0 21
General
Timing marks:
Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre
between compression and power strokes.
Connecting rod
Inside diameter of piston pin bush (with bush pressed into connecting rod). . . . . 40,025...40,040 mm
Outside diameter of piston pin bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,080...44,120 mm
Outside diameter of piston pin bush (oversize 8353 28326). . . . . . . . . . . . . . . . . 44,580...44,620 mm
Interference fit: connecting rod small end bushing-connecting rod. . . . . . . . . . . . 0,057...0,120 mm
Connecting rod small end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025 mm
Connecting rod small end bore (oversize bush) . . . . . . . . . . . . . . . . . . . . . . . . . . 44,500...44,525 mm
Connecting rod big end bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71,730...71,749 mm
84-engines
Inside diameter of piston pin bush (with bush pressed into connecting rod). . . . . 44,025...44,040 mm
Outside diameter of piston pin bush (std) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,080...48,120 mm
Outside diameter of piston pin bush (oversize 8363 38606). . . . . . . . . . . . . . . . . 48,580...48,620 mm
Interference fit: connecting rod small end bushing-connecting rod. . . . . . . . . . . . 0,057...0,120 mm
Connecting rod small end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,000...48,025 mm
Connecting rod small end bore (oversize bush) . . . . . . . . . . . . . . . . . . . . . . . . . . 48,500...48,525 mm
Connecting rod big end bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76,730...76,749 mm
22 0
General
0 23
General
Lubricating system
Oil pressure at normal running temperature:
- at idling speed (min.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 bar
- at running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,5...5,0 bar
24 0
General
0 25
General
Thermostat
Turbocharger
Schwitzer
S1A S1B S2A S2B
Axial clearance max. 0,14 mm 0,14 mm 0,14 mm 0,14 mm
Radial clearance (compressor end) max. 0,61 mm 0,51 mm 0,82 mm 0,95 mm
Compressor wheel locknut torque 6,8 Nm 8,1 Nm 10,2 Nm 15,6 Nm
Compressor housing screws torque 13,6 Nm 13,6 Nm 13,6 Nm 13,6 Nm
Turbine housing screws torque 21,0 Nm 21,0 Nm 21,0 Nm
Schwitzer
S100 S200 S300
Axial clearance max. 0,10 mm 0,10 mm 0,12 mm
Radial clearance (compressor end) max. 0,82 mm 0,88 mm 0,88 mm
Compressor wheel locknut torque 6,8 Nm 13,6 Nm 20,3 Nm
Compressor housing screws torque 13,6 Nm 13,6 Nm 13,6 Nm
Turbine housing screws torque 21,0 Nm 21,0 Nm 21,0 Nm
26 0
General
TIGHTENING TORQUES
Object Nm
Cylinder head bolts and nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm + 90° + 90°
Cylinder head studs to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main bearing screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Connecting rod screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm + 90°
Crankshaft nut, 33/44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Crankshaft nut, 66/74/84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Crankshaft pulley screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Crankshaft pulley screws, 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Flywheel screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Flywheel screws, 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Flywheel housing screws:
- M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
- M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Idler gear screws, 33/44/66:
- M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Idler gear screws (with ball bearing), 66/74/84:
- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
- M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston cooling valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil pump retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil cooler connecting piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Coolant pump pulley screw, 33/44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Coolant pump pulley nut, 66/74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Coolant pump gear nut, 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Belt tightener screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Exhaust manifold screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Always use the torque values listed in the following tables when specific torque values are not available.
0 27
General
SPECIAL TOOLS
Cylinder block
3 4 5
1 2 6
28 0
General
4
6
2
5
0 29
General
8
2 5
9
3 6
4 7
11 12 13 14
10
30 0
General
Crank mechanism
4
1
5 6
3
7 8 9
0 31
General
Coolant pump
2
3 4 5 6
32 0
General
Fuel system
1
2 3 4
0 33
Cylinder Block
WORK INSTRUCTIONS
1. CYLINDER BLOCK
9051 73100
9104 51500 (84)
34 1
Cylinder Block
30°
3. Fit the oil hole of the bushing in 30° angle from hori-
zontal level as picture shows. It is unnecessary to ream
the bushing because it has a correct inner diameter
when it is fitted in place.
1.Remove the camshaft rear end plug and tap the bush-
ings out with a long drift. Observe the different outer dia-
meters when removing.
5 4 3 2 1
Hole diameter
1. 55,62...55,65 mm
2. 55,42...55,45 mm
3. 55,22...55,25 mm
4. 55,42...55,45 mm
5. 55,64...55,67 mm
266 mm
272 mm
134 mm
A-A 7,2...8,0 mm
A
0,1...0,4 mm
5 4 3 2 1
3. Press in a new bushings (2 - 5). Observe the different Note! The cam shaft front end bushing (1) is equipped
outer diameters. Note the position of the oil hole. It is with the oil groove on the outside. Fit the oil hole of the
unnecessary to ream the bushing because it has a cor- bushing in 30° angle from horizontal level (see picture at
rect inner diameter when it is fitted in place. top of the page). The bushing is after assembly in its
correct measures (no need for machining).
1 35
Cylinder Block
Note! Do not drive in the plug too far because it will af- 66-, 74- and 84-engines
fect the camshaft end float.
Order numbers of the oversize camshaft bushings and
hole diameters for the bushings. Numbering begins
from the front end of the engine. Installing places are
F. Oversize bushings for camshaft same as with the standard bushings.
33- and 44-engines
Order no. Hole diameter
If the location of the camshaft bushing (front bearing) is 1. 8368 66036 56,02...56,05 mm
damaged, a bushing with a 0,4 mm oversize outer dia- 2. 8368 52466 55,62...55,65 mm
meter can be fitted. Bushings are available even for ot- 3. 8368 52460 55,42...55,45 mm
her camshaft bearings which do not normally have 4. 8368 52466 55,62...55,65 mm
bushings. Order numbers and machining dimensions 5. 8368 52467 55,84…55,87 mm
for the bushing locations are shown in the figure.
Observe the position of the bushing oil holes. It is unne- G. Fitting plug at camshaft rear end (over-
cessary to ream the bushings after fitting. size bushings)
140 mm 134 mm
7,2...8,0 mm
3
4 3 2 1
0,1...0,4 mm
1
Order numbers of the oversize camshaft bushings and
hole diameters for the bushings, 33-engines. Numbe- 2
ring begins from the front end of the engine.
36 1
Cylinder Block
H. Fitting cylinder liner 5. Fit the cylinder liners and fix each liner with two press
tools 9101 66300. Measure the cylinder liner height with
1. Clean the cylinder liner and its recess in the cylinder a dial gauge and holder 9025 79200. Zero the dial gau-
block. Without o-rings the liner should rotate easily in its ge against a flat surface, for example, the cylinder block
recess. face. Measure each liner in four places. The height of
the liner above the cylinder block face should be
2. Apply a thin layer of marking paint on the underside 0,03...0,08 mm. The height difference between cylinder
of the cylinder liner flange. Fit the cylinder liner without liners under the same cylinder head must not exceed
o-rings and turn it forwards and backwards. Lift out the 0,02 mm, nor must an intermediate cylinder liner lie lo-
liner and check that paint has been deposited on the wer than an outer one.
whole contact surface.
6. If the cylinder liner height is too low, a liner with a
9101 65600
9104 52000 (84) higher flange is fitted.
84-engines
Order no. H Marking-
3. If the recess is damaged, or the cylinder liner height
grooves pcs
(see point 5) needs to be adjusted, use milling cutter
9101 65600 or 9104 52000 (84-engines). If necessary, 8368 67048 9,03+0,02 - (std.)
a light lapping can be executed after milling with the 8368 67050 9,08+0,02 1
help of the cylinder liner. Apply lapping paste to the un- 8368 67051 9,13 +0,02 2
derside of the cylinder liner flange, and twist the liner 8368 67052 9,23+0,02 3
with twisting tool. Lapping is not suitable for adjusting
the cylinder liner height.
Cylinder liners with oversize flanges (higher flanges)
4. Clean the contact surfaces. are marked with grooves on the outer circumference as
follows:
0,03...0,08 mm
1st oversize, 0,05 mm = 1 marking groove
2nd oversize, 0,10 mm = 2 marking grooves
3rd oversize, 0,20 mm = 3 marking grooves
1 37
Cylinder Block
38 1
Cylinder Block
1 39
Flywheel Housing
2. FLYWHEEL HOUSING 4. Clean the seal location and grind off any burrs.
3. Lift the flywheel housing into place and fit all the bolts.
40 2
Flywheel Housing
9052 46300
9104 52600 (84)
- Remove the sleeve and hit the seal into position with
the fitting tool 9052 46300 or 9104 52600 (84-engines).
2 41
Cylinder Head
3. CYLINDER HEAD 2. Compress the valve springs using lever 9101 66200.
Remove the valve cotters, spring guide and spring. Re-
move the valves.
9101 66000
B. Removing valves
Ensure that valves which are to be re-used are marked,
so that they are fitted in their original locations.
9052 47200
9101 66200
42 3
Cylinder Head
21 mm
9101 65900
9101 66100
9101 65800
3 43
Cylinder Head
A B C (mm)
-20' +20'
Inlet 35° 35° 0,7±0,05 (max. 2,20)
Exhaust 45°-20' 45°+20' 0,6±0,05 (max. 2,20)
44,000...44,025 mm
1. Grind the damaged valve disc with a valve refacer.
Adjust angles to 45°-20' for exhaust valves and 35°-20'
for inlet valves.
Inlet
2. If the edge of the valve head is less than 1,5 mm after
11±0,1mm it has been ground, or if the valve stem is bent, the valve
should be discarded.
4. Lap the valves with lapping paste and check the con-
tact surface with marking paint.
48,500...48,525 mm
5. Clean the cylinder head and valves of any remaining
lapping paste.
3. Clean the valve seat location. Cool the new seat ring
in liquid nitrogen until it stops bubbling, or alternatively H. Fitting valves
place it in dry ice.
1. Check the valve springs for straightness, length and
4. Fit the seat with a suitable drift. Machine the seat. tension using a spring tester. See “Technical data”,
point “Valves, rockers and tappets”.
Note! Where necessary, standard size seats can be
replaced by inserts with a larger outer diameter. See 2. Lubricate the valve stems and fit the valves in the cor-
“Technical data”, point “Cylinder head”. rect order in the cylinder.
The inlet valve seat machined direct on the cylinder 3. Fit the springs, spring guides and valve keepers with
head, can be provided with a separate valve seat ring, the aid of a lever for compressing valve springs, 9101
order no. 8366 47936. Machine the seat insert location 66200.
on the cylinder head (see picture above). Fit the insert
like a seat of the exhaust valve. 4. Tap the end of the valve stems lightly after fitting the
valve in order to ensure that they are secure.
44 3
Cylinder Head
I. Fitting cylinder head 5. Tighten the cylinder head bolts progressively as fol-
lows:
1. Measure the length of the cylinder head bolts. Com-
pare with dimensions shown in figure below. Change 1. First tightening to 80 Nm
too long bolts. 2. Tightening of 90°
3. Tightening again of 90°.
max. 142 mm
Note! After this the cylinder head does not need retigh-
tening.
3. Check that the sealing surfaces are clean and fit the
cylinder head gasket(s) and the cylinder head(s). Ensu-
re that on the six cylinder engines both cylinder heads 50 Nm
are parallel by fastening lightly the exhaust manifold be-
fore tightening the cylinder head bolts (the exhaust ma-
nifold can damage, if the heads are not parallel). Clean
and lubricate and fit the bolts.
13
12 2 4
8 6 11
22 19 12 6 4 11 14 17
21
10 2 7 16
20 8 1 9 15
18 3 5 13
44
3 45
Valve Mechanism
4. VALVE MECHANISM
60°
5. Fit the plug to the other end of the rocker arm shaft.
Lubricate the shaft and fit various parts in a correct or-
der. Note the correct position of the shaft and the bea-
ring brackets. The split side of the bracket and the shaft
oil holes must be turned to the valve side (see pictures
above). Fit the other end plug.
4. Check diameter of the rocker arm bore, B. Changing camshaft / camshaft gear
23,000...23,021 mm. Change the worn or damaged
rocker arm. Where necessary grind the rocker arm val- 1. Remove the valve cover. Remove the rocker arm
ve contact surface to the correct shape. Do not grind mechanism.
more than necessary as the hardened layer is thin.
2. Remove the radiator, cooling fan, alternator and the
V-belt.
46 4
Valve Mechanism
C. Adjusting valves
The valve clearance, which can be adjusted on a hot or
cold engine, is 0,35 mm for both inlet and exhaust val-
ves. The clearance is adjusted when the respective pis-
ton is at T.D.C. in the compression stroke. The valves
for the different cylinders are adjusted in the same se-
quence as the order of injection.
0,35
5. Connect the push rods in pairs, using o-rings or elas-
tic bands to prevent them from falling through.
12. Free the push rods and fit the rocker arm
mechanism. Adjust the valves. Fit the valve cover.
33
13. Fit the other removed parts.
Check the valve clearances in the injection order of the
engine. Injection order is 1 - 2 - 3.
4 47
Valve Mechanism
44-engines
44
66, 74, 84
48 4
Valve Mechanism
4 49
Crankshaft
5. CRANKSHAFT
A. Removing crankshaft
1. Remove the oil sump.
7. Remove the main bearing caps and lift out the crank- Note! When grinding note that the journal edges must
shaft. remain round.
9052 48800
50 5
Crankshaft
84-engines, break the crankshaft gears using e.g. a 3. Lubricate the bearing surfaces and fit the crankshaft.
grinder. Grind the gears enough. Hit the gears apart Fit the crankshaft thrust bearings with the lubricating
with a chisel. Do not damage the crankshaft! grooves facing the crankshaft.
7
9103 94700
6
4. Fit the main bearing caps according to their numbe-
ring (bearing lock in the block and in the cap are on the
3. Heat the new gears to 220...250°C. Tap them onto same side), the rear with thrust bearings provided with
the shaft with drift 9103 94700. Note the position of the guide lugs. Lubricate the bolts and tighten them to
key and ensure that the aligning marks on the front gear 200 Nm.
are visible. Leave it to cool.
0,10...0,38 mm
D. Fitting crankshaft
1. Clean the oilways, bearing shells and bearing loca-
tions. Check that the crankshaft is clean.
2. Assembly the bearing with oilholes/groove (A) to the Note! 33-engines, tightening torque of screws of crank-
cylinder block and the bearing with no hole (B) to the shaft counterweight is 160 Nm. Apply locking fluid (e.g.
bearing cap. Ensure that the bearing shell clamping Loctite 2701) on the screw threads.
claws fit into their notches and that the shells to be fitted
in the cylinder block have a hole coinciding with the oil
port.
5 51
Crankshaft
OK
OK
OK
When fitting the hub piece to the crankshaft front end
note the correct position of the hub (engines with the
2. Check also the condition of the rubber element. If
installation mark of the injection pump on the crankshaft
rubber pieces have been loosened from the element,
pulley/vibration damper). The hub piece has an installa-
rubber has been pressed to the depth of more than
tion mark - on two teeth and the corresponding installa-
3,5 mm or the outer circumference is slack or it moves
tion mark o of the crankshaft is on one tooth.
in the direction of the shaft, change the damper.
2
max. 1,5 mm
A
3
1
4
52 5
Crankshaft
Note! Even a small dent makes the vibration damper 5. Make the installation mark of the injection pump on
inoperative. Do not remove it by turning forcibly and be the vibration damper/pulley with an electric pen (do not
careful not to damage it when it is loose. If you detect a tap).
dent on the outer surface, do not install the damper
back in the engine. Piston distance (h) from top dead centre vs. crank angle
(α) with different injection pumps.
Note! Note! Make the installation mark of the injection
pump on the vibration damper with an electric pen (do Engine Bosch VP 30 Bosch VP 44
not tap). type α h (mm) α h (mm)
44 30° 10,213
66 30° 10,213
H. Changing crankshaft pulley / vibration
74 30° 11,692 26° 8,865
damper
84 28° 10,997
5 53
Connecting Rods and Pistons
6. CONNECTING RODS AND PIS- 3. If the piston pin bushing is worn, it should be driven
out using a suitable drift
TONS
Ø5 mm
A. Removing pistons together with con- Ø4 mm (84)
necting rods
40,025...40,040 mm
44,025...44,040 mm (84)
1. Remove the oil sump and the oil inlet and pressure
pipes.
Piston pin bushing 1. Fit the bearing shells together and tighten the screws.
1. Clean the connecting rod and bearing shells. 2. Measure the I.D. using a cylinder gauge which has
been zeroed to the diameter of the respective bearing
journal. If the clearance exceeds 0,14 mm with new
bearing shells, the big end journals require grinding.
Refer to the specifications for the correct undersize and
the corresponding bearing.
54 6
Connecting Rods and Pistons
84-engines
Letter Order no. Weight
(B)
E 8368 64101 2230 - 2249 g
F 8368 64102 2250 - 2269 g
G 8368 64103 2270 - 2289 g
H 8368 64104 2290 - 2309 g
I 8368 64105 2310 - 2329 g 3. Measure the piston ring gap by pushing one piston
J 8368 64106 2330 - 2349 g ring at a time into the cylinder bore. The piston ring gap
must not exceed 1 mm on 1. and 3. piston rings and 1,5
K 8368 64107 2350 - 2369 g
mm (84-engines, 1,3 mm) on 2. piston ring.
6 55
Connecting Rods and Pistons
4. Fit the piston rings on the piston using the piston ring
pliers. Ensure that the rings are fitted in the correct
groove and that "TOP", or the manufacturer's designa-
tion, faces upwards.
56 6
Connecting Rods and Pistons
9020 01100
9105 18700 (84)
6 57
Counterbalance
7. COUNTERBALANCE (44-engines) rings. Apply thread lock fluid (e.g. Loctite 270) to the
locking screws, and lock the shafts.
58 7
Counterbalance
20°
2. Heat the gear rim with a welding torch and drive it off
using a suitable drift.
3. Heat the new gear rim to max. 250°C. Fit the gear rim
with the chamfer facing the crankshaft flange, and with
the teeth according to markings or according to figure
above. Tap the gear rim down and leave it to cool.
7 59
Flywheel
8. FLYWHEEL
B. Fitting flywheel
1. Clean the contact surfaces on the crankshaft rear
flange and on the flywheel.
60 8
Flywheel
8 61
Timing Gear Assembly
9. TIMING GEAR ASSEMBLY 7. Unscrew the idler gear bolts (17 and 22 mm). Remo-
ve the flange, gear wheel and bearing journal.
33-, 44-, 66- and 74-engines
8. Extract the camshaft.
1. Drain the engine oil and remove the oil sump. 10. Remove the crankshaft front sealing ring from the
front casing and clean all the parts that have been re-
2. Remove the radiator, fan, alternator, belt tensioning moved.
and belt (if not removed earlier). If the engine is equip-
ped with an air compressor or air conditioner, it has to
be removed.
B. Reconditioning idler gear
0,10...0,25 mm
Ø55,00...55,03
30 mm
9101 65700
9024 55800
62 9
Timing Gear Assembly
1
2 Do not open!
200 Nm
60 Nm 35 Nm
1. Chuck of lathe
2. Roller 5 mm
4. Fit the idler gear with shaft stud and ensure that the
markings are in the correct position. Fit the washer and
Machine the idler gear bushing inner diameter to a cor-
tighten the bolts to the correct torque.
rect dimension after fitting. Centre the idler gear accor-
ding to figure above so that tooth backlash is kept the
same.
2. Fit the injection pump together with gear wheel (if re-
moved).
6. Fit the oil deflector ring on the crankshaft and fit the
timing gear casing cover using a new gasket. Drive in
the tension pins with drifts 9025 98700 and 9025 98800
respectively (the tubular pin round the screw stud).
Tighten bolts and nuts.
9 63
Timing Gear Assembly
9030 15200
7. Fit the protective plate into the seal location and fit the
crankshaft front seal with special tool 9030 15200.
6
35 Nm
9025 98900
30 Nm
4 22 Nm
180 Nm
64 9
Timing Gear Assembly
E. Power take-off
In the engines is used a transmission that can be equip-
ped with a PTO run from the camshaft gear. The PTO
30 Nm can run e.g. a hydraulic pump.
A35x31
DIN 5482
m = 1,75
z = 18
9 65
Timing Gear Assembly
9. TIMING GEAR ASSEMBLY 7. Unscrew the idler gear screws and remove the idler
gear (broad timing gear casing).
84-engines
8. Extract the camshaft.
1. Drain the engine oil and remove the oil sump. 10. Remove the crankshaft front seal ring from the front
casing cover and clean all parts removed.
2. Remove the radiator, fan, alternator, belt tensioning
and belt (if not removed earlier). If the engine is equip-
ped with an air compressor or air conditioner, it has to
be removed. B. Fitting timing gear casing
3. Remove the crankshaft belt pulley and the vibration The position of the timing gear casing and cover is de-
damper. termined by two tension pins. Therefore centring should
not be undertaken in connection with fitting. However,
Note! When removing the hub piece from the cranks- the backlash between the different gears should be
haft front end mark the correct position of the hub. checked. Casing and covers that are delivered as spare
parts also have holes for the tension pins already ma-
chined.
9104 53300
Note! Do not remove the nut completely first. The 1. Screw in the thread piece M14/M8 to the cylinder
hub will be dashed dangerously when it is loosen. block (narrow timing gear casing). Fit the casing with a
new gasket against the cylinder block. Hit in the tension
5. Remove the cooling pump, observe the retaining sc- pins with drift 9025 98700. Tighten screws and nuts.
rews on the injection pump side. Remove the timing
gear casing cover. 2. Fit the injection pump and its gear wheel (if removed).
6. Remove the injection pump. See instruction 13 C. 3. Lubricate the camshaft bearings and insert the shaft
in the cylinder block. Release the push rods and tappets
Note! If the timing gear casing is not to be changed, the if they have been suspended.
injection pump can remain in place. In which case dis-
connect all leads and pipes from the pump. (Bosch P in-
jection pump, loosen bottom mounting from the pump.)
66 9
Timing Gear Assembly
Do not open!
9104 34600
Position of the timing marks. 5. Fit the guide pin 9104 34600 instead of the idler gear
bolt. Fit the camshaft axial controller in the cover (apply
Narrow timing gear casing sealing compound to the thread) and fit the cover. Hit in
the tension pins.
With the broad timing gear casing skip to the point 8.
Note! If the crankshaft oil throwing ring is removed, fit it
(drift 9103 94900) before fitting the cover.
180 Nm
180 Nm
22 Nm
22 Nm
22 Nm
9 67
Timing Gear Assembly
9104 05400
80 Nm
1000 Nm
13. Lubricate both the seal and sealing surfaces and fit
9. Tighten the guide bolts in the guide unit frame and the crankshaft hub. Lubricate the crankshaft nut threads
position the unit on the idler gears as in picture (guide and tighten the nut to 1000 Nm.
bolts in the idler gear shaft holes and housing holes).
Tighten the idler gear bolts through the guide unit holes, 14. Fit the other removed parts.
tighten 180 Nm. Remove the guide unit.
11. Fit the drive unit shaft and camshaft axial controller
in the front cover (apply sealing compound to the 350 Nm
thread). Fit the cover and hit in the tension pins. Obser-
ve the idler gear shaft bolt seals. Fit the drive unit rear
bearing and cover.
68 9
Timing Gear Assembly
3. Tap the blocking plug (if mounted) in its place with fit-
ting drift 9025 87400.
4. Fit the belt pulley, washer and nut. Tighten the nut to
350 Nm.
9 69
Lubrication System
Loctite 638
60 Nm
3. Apply locking fluid (e.g. Loctite 638) onto outside of 1. Fit the gear wheels in the pump body. Fit the cover
the valve seat. Tap the new valve seat in the cylinder using a new gasket. Partly tighten the screws. Rotate
block using a suitable drift. Place the spring with valve the pump shaft and tap the side of the cover lightly until
plate into the cylinder block and fit the cover with a new the position is reached where the shaft rotates most
gasket. freely. Tighten the screws and check that the shaft still
rotates freely.
2. Fit the drive gear onto the shaft. Apply locking fluid
B. Removing and dismantling lubricating (e.g. Loctite 242) onto the nut threads and tighten the
oil pump nut to 60 Nm. Remember the washer under the nut.
70 10
Lubrication System
90°
Fit the oil sump gasket with the silicone stripes against
the cylinder block (self carrying and casted oil sumps).
10 71
Lubrication System
To remove
1. Open the coolant drain plug under the oil cooler and
drain the coolant into a suitable container. Remove the
pipe going into the thermostat housing.
2. Remove the turbo oil pipes and the oil pressure pipe
from the cylinder block. Remove the oil filter. Drain the
60 Nm oil into a container.
3. Remove the oil cooler from the engine. Open the coo-
ler housing and remove the guide plate. Unscrew the
cell screws and remove cell from the body. Clean the all
parts.
2. Fit new sealing rings. Fit the cooler with draining plug
turned downwards. Connect coolant pipes in the correct
way.
84-engines
50 Nm
2. Push the guide plate between the cell and the body
and fit the housing. If needed now can the water side be
pressure tested, test pressure 5 bar.
4. Fill the coolant system. Start the engine and check for
leakages.
8363 36459
72 10
Lubrication System
°C
+40 min. 9,5 max. 11,5 dm3
+30 44
+10
SAE 20W-20
SAE 20W-40
SAE 15W-40
0
SAE 10W-40
SAE 10W-30
SAE 5W-40
-20
66
-40
74
84
min. 42,0 max. 46,5 dm3
1 dm3 = 1 litres
10 73
Cooling System
B. Thermostat
Check the function of the thermostat as follows:
• Lower the thermostat into a vessel of boiling water
Some 66- and 74-engines have two separate thermos-
so that the thermostat does not touch the sides or
tats. These are separated from the type of the single
bottom.
thermostat and they are not interchangeable. To these
• Opening must begin under 20 seconds. engine there are no separate winter thermostats.
• The thermostat must be fully open under 50 sec-
onds. Stroke, see "Technical data" point "Ther-
mostat".
74 11
Cooling System
To replace 6. Tap out water and shaft seals using a drift. Clean the
parts and inspect their condition. Replace faulty or worn
1. Put the thermostats in position in the housing. Fit a parts with new ones.
new gasket and the outlet cover. For guiding you can
use M8 studs (2 pcs). Observe the plate (if mounted) Note! If the pump bearings have to be changed, use a
that comes on top of the smaller thermostat. Fit the gas- reconditioning kit. This kit also contains all seals (see
ket so that the bigger hole is on the same side as the Parts Catalogue).
plate.
7. Drive in the new shaft seal in the housing using a sui-
2. Connect the top hose and fill the cooling system. table drift. Put the bearings and the intermediate sleeve
onto the shaft. Grease bearings with heat-resistant ball
bearing grease (NLGI 2). Fit the shaft and the bearings
in such a way that the pressing force is not transmitted
by the bearing balls. Fit the circlip for the bearing.
11 75
Cooling System
9051 79300
0,8...1,2
120 Nm
9,0...9,3
80 Nm
Loctite 572
10. Fit the rear plate to the cylinder block using a new
seal. Use guide pin (Ø8 mm) in the hole shown with ar-
row in the picture above. Apply sealing compound to the
thread of screw.
76 11
Cooling System
D. Coolant pumps with heavy duty bea- Note! If the pump bearings have to be changed, use a
rings pump repair kit. This kit also contains all seals (see
Parts Catalogue).
66- and 74-engines
180 Nm
0,8...1,2
120 Nm
E. Reconditioning the coolant pump 8. Hit the water seal into its position with tool 9103
41100. Press the impeller to its position (towards the
84-engines shaft shoulder) supporting the shaft from the other end.
Make sure that the shaft can rotate freely.
1. Drain the coolant. Disconnect the hose at the inlet
connection of the coolant pump. Loosen the coolant pi- 9. Fit the gear on the shaft and tighten the nut to
pes from the coolant pump. 180 Nm.
2. Release the three screws which retain the coolant 10. Fit the pump housing using new gasket.
pump to the cover of the timing case-from the rear. Re-
move the coolant pump. 11. Fit the pump using new o-ring.
3. Unscrew the gear fixing nut and remove the gear. Re- Note! If both coolant pump and injection pump are re-
move the pump housing from the pump body. moved, fit the coolant pump first (one fitting screw can
not be fitted as injection pump is in position).
4. Remove the circlip in the pump body. Press the shaft
together with bearings in the direction of the gear.
5. Tap out the water seal and shaft seal using a drift.
Remove o-ring seals and clean the parts and inspect
their condition. Replace faulty or worn parts with new
ones.
11 77
Inlet and Exhaust System
12. INLET AND EXHAUST SYSTEM 5. Remove the manifold if necessary. Clean the sealing
surfaces and remove any carbon deposits. Check that
the sealing surfaces are flat. If the fastening flanges are
twisted or there are scratches on the sealing surfaces,
An engine that is equipped with a turbocharger is a gre- machine the flanges or renew the exhaust manifold.
at deal more sensitive to disturbances and impurities in
the inlet and exhaust systems than a naturally aspirated 6. Ensure that no loose objects or impurities have ente-
engine. Therefore special attention should be given to red the exhaust pipe or the silencer. Any such loose ob-
the whole inlet and exhaust system. jects or impurities can increase the back pressure for
the exhaust gases from the turbine wheel.
Note! The safety filter inside the main filter should not
be removed unnecessarily, for checking or cleaning.
The safety filter must not be cleaned, but should be
changed when necessary.
78 12
Inlet and Exhaust System
D. Fitting turbocharger
Locate the cause of the defects on the turbocharger.
Remedy the fault before fitting the new turbocharger.
3. Check the turbine shaft running clearance. Place the 1. Check the tightness of the intake and exhaust mani-
stylus of a dial gauge against the shaft and move the folds, and that they are securely fastened. Ensure that
shaft sideways. refer to the clearance given in the spe- there are no loose carbon or rust particles, or other fo-
cifications. See "Technical data" point "Turbochar- reign objects in the manifolds.
ger".
2. Connect the turbocharger to the exhaust manifold
and tighten down using a new gasket.
4. Check the shaft end float. Place the stylus of the dial 4. Pour abt. 0,1 litres of pure engine oil into the bearing
gauge against the end of the shaft and move the shaft housing before attaching the pressure oil pipe. This is
axially. Refer to the clearance given in the specifica- very important in order to ensure that the turbocharger
tions. See "Technical data" point "Turbocharger". is lubricated at the time of starting.
If any defects or wear are confirmed, the turbocharger 5. Connect the pressure and return oil pipes. Use a new
should be reconditioned. seal. Check that there are no tensions in the pipes when
tightening.
If the engine does not work correctly and the turbochar-
ger is not defective or too worn, the fault could be traced 6. Start the engine and check that there are no leaks.
to one of the following items:
12 79
Fuel System
Fortius series engine fulfils the emission requirements set by authorities (EU97/68/EC Stage 2 and EPA 40 CFR 89
Tier 2). The manufacturer guarantees that all engines of this type are equivalent to the engine that is officially ap-
proved. This must be noticed especially when performing periodical maintenance, follow carefully the service
schedule. Any adjusting and repair work for the injection system or the engine control unit can only be made by a
representative authorized by Sisu Diesel Inc. When performing any service or repair work use only original SisuDie-
sel spare parts. Inadequate or delayed service and the use of other than original SisuDiesel spare parts invalidates
the responsibility of Sisu Diesel Inc. on the fulfilment of the emission requirements.
Note! This manual gives only general instructions for repair and service measures related to the fuel system. This
applies particularly to changing of the injection pump which can be done only by a specially trained person who has
the necessary special tools and gauges. All service and repair work related to the fuel system requires special care
and cleanliness!
Injectors
Order no. Manufacturer Type Nozzle no. Opening pres- Setting pres- Code
sure bar sure* bar
8368 54791 Stanadyne M 8368 54792 270+8 278 876
8368 54940 Stanadyne M 8368 54941 270+8 278 301
8368 54929 Stanadyne M 8368 54930 270+8 278 234
8368 54992 Stanadyne M 8368 54991 270+8 278 625
8366 59808 Stanadyne M 8366 59902 270+8 278 358
8367 64613 Stanadyne M 8367 64614 270+8 278 927
*)Value to be used when adjusting the opening pressure of a new or used injector.
Adjusting plate for injector (1,00…2,00 mm) order no. 8368 62000…8368 62020.
Tightening torques
80 13
Fuel System
A. Removing injectors 2. Secure the injector in a test bench and check the fol-
lowing:
1. Clean the injectors and the area around them. Dis-
connect the delivery pipes and the leak-off pipes. • injector opening pressure
• the properties of the chattering (creaking) sound
9051 71300 and the form of the spray pattern
• sealing of nozzle valve against its seat.
Opening pressure
Tightness of nozzle
Press down the tester pump lever until the pressure ri-
ses to approx. 20 bar below the adjusting value. Main-
tain this pressure for approximately 10 seconds and
check whether drops of fuel are formed on the point of
the nozzle. If the injector leaks, it should be cleaned or
the nozzle should be changed.
13 81
Fuel System
9101 66000
Injector
1. Fuel inlet 9 2
2. Leak-off pipe connection
3. Adjusting shim
4. Pressure spring
5. Pressure pin
6. Nozzle body
7. Pressure chamber 3 1
8. Injector needle 1. Washer
4 2
9. Number code 2. Rubber ring
3. Sealing washer
5
6
7
3
8
82 13
Fuel System
Note! The screw studs in the cylinder head for the injec-
tors should only be finger tight. If tools have to be used
the studs should be tightened only lightly.
2. Fit the pipes without tension and check that they are
at right angles to the union. Tighten the delivery pipe at-
taching nuts to 25 Nm. Do not overtighten!
13 83
Fuel System
Technical data
Injection pump
Fuel system
Tightening torques
84 13
Fuel System
7 2
9 3
The fuel is pumped by feed pump from the tank via a The fuel system is equipped with a pressure sensor that
pre-filter, trough the filter to the injection pump. The in- alarms before interference has developed. An option
jection pump forces the fuel into the injector that feeds the pre-filter can be equipped with a see-trough water
fuel into the combustion space in fine spray. Excess fuel trap and with an electronic water in fuel sensor.
returns from the fuel injection pump through an overflow
valve to the fuel tank. The overflow pipe between filter
and injectors helps the automatic bleeding of the sys-
tem.
13 85
Fuel System
Note! If the measured pressure is below the given va- 1. Turn the crankshaft to a position where the 1st cylin-
lue, cause may be: der piston reaches its compression stroke top dead
centre. Turn the crankshaft backwards until the mark on
• Clogged fuel filters. the pulley passes the timing indicator. Then rotate the
crankshaft slowly in running direction until the mark on
• Malfunction of the feed pump.
the pulley is at the point of the timing indicator.
• Suction piping clogged or leaking air.
• Empty fuel tank or unsuitable fuel (e.g. summer 2. Clean the conic connection between the shaft of the
fuel in the winter). injection pump and coupling flange and fit the separate
coupling flange on the shaft of the injection pump. Do
not tighten the nut!
86 13
Fuel System
1 12. Fit the injection pipes and check that they are in cor-
rect angles to the unions. Tighten the delivery pipe atta-
ching nuts to 25 Nm. Do not overtighten!
7. Open the lock screw (1) a little and fit the plate (2), 13. Fit the fuel pipes, throttle cable and the electric wire.
that came with the pump, under the screw. Tighten the
screw to 12,5 Nm. The shaft of the injection pump is 14. The fuel system bleeding starts with opening the
free now. fuel return pipe connection and pumping with the hand
pump until the injection pump housing is filled with fuel.
Tighten the connection. Open the injection pipe connec-
tions from the injector end (only about half turn, not mo-
re). Crank the engine for about 5 seconds, until fuel
comes out from every injection pipe. Tighten the injecti-
on pipe connections and start the engine. Clean off the
over flown fuel.
8366 62521
Note! If needed, a vacuum pump can be connected to
Setting tool for the injection pump. Adapter 8366 62521 the fuel return connection. The pump sucks the fuel
and dial gauge (1/100 mm). from the tank via the injection pump. Connect the return
pipe when fuel flows out from the return connection.
13 87
Fuel System
Technical data
Injection pump
Fuel system
Tightening torques
88 13
Fuel System
9
3
5
6
8
1
The fuel is pumped by electric feed pump from the tank The fuel system is equipped with a pressure sensor that
via a pre-filter, trough the filter to the injection pump. alarms before interference has developed. An option
The injection pump forces the fuel into the injector that the pre-filter can be equipped with a see-trough water
feeds fuel into the combustion space in fine spray. Ex- trap and with an electronic water in fuel sensor.
cess fuel returns from the fuel injection pump through
an overflow valve to the fuel tank. The overflow pipe
between filter and injectors helps the automatic blee-
ding of the system.
13 89
Fuel System
90 13
Fuel System
S
G EAL
AS A
KE NT
T
35 Nm
A = O-ring seals
NT
T
GASK E
SE ALA
Parallel
PS/2 USB
1
2
13 91
Fuel System
5. Fit the pipes without tension and check that they are
at right angles to the union. Tighten the delivery pipe at-
taching nuts to 25 Nm. Do not overtighten!
37990
0470006004
Made in Germany
ming housing.
9109 80100
283
41098
011
Made in Germany
0470506042
BOSCH
142351
000
92 13
Fuel System
+15°C. A
by the manufacturer. 2 3 4 5 6 7 8
VISCOSITY cSt
13 93
Engine Control System
Fortius series engine fulfils the emission requirements set by authorities (EU97/68/EC Stage 2 and EPA 40 CFR 89
Tier 2). The manufacturer guarantees that all engines of this type are equivalent to the engine that is officially ap-
proved. This must be noticed especially when performing periodical maintenance, follow carefully the service
schedule. Any adjusting and repair work for the injection system or the engine control unit can only be made by a
representative authorized by Sisu Diesel Inc. When performing any service or repair work use only original SisuDie-
sel spare parts. Inadequate or delayed service and the use of other than original SisuDiesel spare parts invalidates
the responsibility of Sisu Diesel Inc. on the fulfilment of the emission requirements.
11
10
94 14
Engine Control System
The sale and supply of the service tool and the additio-
nal parts is done by Sisu Diesel Inc. Service Depart-
ment.
14 95
Engine Control System
The service tool can be connected using the adapter if A. Changing of Control Unit (ECU)
the engine is using any of following wiring harness:
Manufacturer
SISU Diesel Inc.
FIN-37240 Linnavuori
FINLAND
EEM 2
Engine Control Unit
Hw. ver.
Partno 836864630
Cust.
Partno
Engine
Serial nr M07575
Type 74 ETA
96 14
Engine Control System
3
2
1
1. Ground
2. Rpm signal
3. +12 V
015
042401
3 2 1
283
41098
011
Made in Germany
0470506042
1. Ground
2. Pressure signal
3. +5 V
BOSCH
142351
000
14 97
Electrical System
A. Alternators
Bosch N1 28 V 10/80 A (SisuDiesel no. 8353 39751)
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Output
1500 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 A
2700 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53,5 A
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 A
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,8 mm
Brush length when new. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm
Min. brush length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5...8,2 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,057...0,062 ohm
Regulating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 V
Tightening torques:
Shaft nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,1...5,5 Nm
Regulator screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
Joint B- (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,8...6,8 Nm
Joint W (M5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
Joint D+ (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5...8,0 Nm
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Output (warm generator, testing voltage 26 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 A
3500 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 A
7000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 A
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,8 mm
Brush length when new. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm
Min. brush length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5...8,2 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,038...0,041 ohm
Regulating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28,5 V
Tightening torques:
Shaft nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,1...5,5 Nm
Regulator screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
Joint B- (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,8...6,8 Nm
Joint W (M5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
Joint D+ (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5...8,0 Nm
98 15
Electrical System
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,9 mm
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,5 mm
Min. brush length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Tightening torques:
Shaft nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60...70 Nm
Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Output (test voltage 13 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 A
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 A
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 A
Charge begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150 r/min
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 000 r/min
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 mm
Min. brush length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,70...2,97 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,60...1,80 ohm
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50...70 Nm
2. Joint B+ (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,2...6,0 Nm
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
4. Joint W (M 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
1 3
15 99
Electrical System
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Output (test voltage 13 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 A
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 A
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 A
Charge begins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 r/min
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 000 r/min
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,3 mm
Min. brush length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,70...2,97 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,33...0,36 ohm
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50...70 Nm
2. Joint B+ (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,2...6,0 Nm
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
4. Joint W (M 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
100 15
Electrical System
B. Starters
Iskra AZJ3319 12 V 3 kW z10 (SisuDiesel no. 8366 62073)
Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8000 r/min
Amperage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 A
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1375 A
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Nm
Brush length (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mm
Min. brush length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30...35 N
Tightening torques:
Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 Nm
Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Screws on solenoid (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,0 Nm
Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Brush holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Lever pin on engagement lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Contact screws on solenoid switch (M8) . . . . . . . . . . . . . . . . . . . . . 8,5 Nm
Contact screws on solenoid switch (M10) . . . . . . . . . . . . . . . . . . . . 13 Nm
Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 000 r/min
Amperage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 A
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 A
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
Brush length (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mm
Min. brush length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30...35 N
Tightening torques:
Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 Nm
Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Screws on solenoid (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,0 Nm
Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Brush holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Lever pin on engagement lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Contact screws on solenoid switch (M8) . . . . . . . . . . . . . . . . . . . . . 8,5 Nm
Contact screws on solenoid switch (M10) . . . . . . . . . . . . . . . . . . . . 13 N
15 101
Optional Equipment
A. Compressor (Bendix)
A 5 6 D 3
7
C 2 4
G 1
10
8
11 H
140 Nm 12
Disassembly
1. Remove the retaining screws (A, 11 pcs.), take off the 4. Remove the unloader spring and saddle as well as
cylinder head and the valve plate. Remove the inlet val- the pistons and the o-rings seals.
ve heads, springs, valve guides and gasket.
5. If necessary, remove the rear end cover and its o-ring
2. Loosen the retaining screws (D, 2 pcs.) and detach seal and the bottom cover with its gasket.
the cylinder head from the valve plate. Remove the de-
livery valve heads, springs and gasket. Note! Do not try to remove the valve seats. They are
pressed in during manufacture and are integral parts of
3. Remove the retaining screws of the air filter (if as- the crankcase.
sembled) and take off the filter and the gasket.
102 16
Optional Equipment
Reassembly
1. Fit a new o-ring seal in its groove and place the end
cover in its position by pushing from the back. Tighten 30 Nm
the cover retaining screws evenly to 17...23 Nm.
2. Fit the bottom cover with a new gasket in place (if re-
moved). Tighten the cover retaining screws evenly to
8...10 Nm.
4. Fit the delivery valve heads and springs into the valve
plate. Insert a new gasket and fix the valve plate in the
cylinder head. Tighten the screws to 5,4...8,1 Nm. En-
sure that the valve heads move freely. DO NOT LUBRI-
CATE THE VALVE HEADS OR SPRINGS! 22 Nm
60 Nm
5. Fit the inlet valve head guides into their recesses with
the cut-away sides towards their respective cylinder bo-
res. Assemble the inlet valve heads and the springs. Fit
the cylinder head using a new gasket. Tighten the retai-
ning screws evenly to 20,3...23,0 Nm. Ensure that the
valve heads move freely. DO NOT LUBRICATE THE
VALVE HEADS OR SPRINGS!
6. Attach the air filter (if necessary) and use a new gas-
ket.
16 103